oil dipstick LAND ROVER DISCOVERY 1995 User Guide

ZF
7
REPAIR Accessories removal/fitting
If fitting a replacement transmission assembly to the
vehicle, remove the following items from the existing
assembly and fit to the replacement.
CAUTION: It is important to remove the
spacer from the extension shaft and fit
onto the replacement unit.
50.Breather pipe union and washers from main
gearbox.
51.Breather pipe, union and washers from transfer
gearbox.
52.Main gearbox selector lever.
53.RH mounting bracket assembly.
54.Oil cooler pipe unions.
55.Fit blanks to all apertures where unions have
been removed and blank off pipe ends.
Refit
1.Fit transmission to cradle and hoist.
2.Locate hoist under vehicle and remove torque
convertor retaining strap.
3.Ensure low range gear is engaged.
4.Apply approved sealant to bell housing face.
5.Carefully raise assembly, align bell housing with
flywheel housing and bring mating faces
together.
6.Fit nuts and bolts to secure transmission to
engine.
7.Locate electrical wiring and breather pipes to
position.
8.Secure kick down cable clip to bell housing.
9.Raise hoist sufficiently to take weight.
10.Remove block and jack from engine sump.
11.Fit filler/dipstick tube to gearbox sump and
secure bracket to bell housing.
12.Apply Loctite to torque convertor bolts
13.Working through starter aperture refit the four
torque convertor to flexible drive securing bolts,
rotating crankshaft to gain access to bolt
locations.
14.Refit starter and heatshield.
15.Secure breather pipes and harness with ties.
16.Fit left hand mounting bracket assembly to
gearbox.
17.Raise transmission and support with a suitable
ramp [hoist] jack.
18.Remove two bolts securing transmission to
cradle, lower hoist and remove from under
vehicle.
19.Apply Loctite to above bolts and fit to transfer
gearbox input bearing support plate.
20.Fit chassis cross member.21.Secure gearbox mounting brackets to chassis
cross member.
22.Remove ramp [hoist] jack.
23.Connect electrical leads to differential lock
switch.
24.Connect inhibitor switch multi-plug.
25.Connect selector cable to lever on side of
gearbox.
26.Connect oil cooler pipes to gearbox and secure
retaining bracket to gearbox sump.
27.Secure silencer to chassis and refit exhaust front
pipe.
28.Refit front propeller shaft to transfer gearbox.
29.Refit rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
30.Connect speedometer cable to transfer gearbox.
31.Refill transfer gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
32.Lower ramp [hoist] to ground level.
33.Reconnect turbo-charger hose to inter-cooler.
34.Reconnect top hose to radiator.
35.Refill cooling system with correct mixture of
coolant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
36.Reconnect kick down cable to fuel injection
pump.
37.Secure breather pipe clip to rear of cylinder
head.
38.Engage harness with clips along top of
bulkhead.
39.On left hand drive vehicles only, connect
multi-plug to top of brake fluid reservoir.
40.Refit insulation pad to rocker cover and inlet
manifold, secure with oil filler cap.
41.Refit gaiter and knob to transfer gear lever.
42.Select high range gear.
43.Reconnect battery terminals.
44.Refill main gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids

ZF
9
REPAIR OIL SUMP
Service repair no - 44.24.05
Remove
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Raise vehicle.
4.Drain oil and refit plug with new seal.
5.Detach heat shield at front exhaust pipe to
manifold.
6.Disconnect electrics from Lambda sensors.
7.Remove catalytic converter assembly.
8.Remove chassis cross-member from under
gearbox.
9.Disconnect dipstick tube at oil sump. Loosen
securing bolt at bell housing and move dipstick
aside.
10.Remove clamps securing oil sump. Note their
locations for refit and withdraw sump.
11.Remove gasket and clean gasket mating faces.Refit
12.Refit oil sump using a new gasket.
13.Connect dipstick tube to oil sump and tighten
bolt at bell housing.
14.Refit chassis cross member.
15.Refit catalytic converter assembly
16.Connect electrics to Lambda sensors.
17.Connect heat shield front pipe to manifold.
18.Connect battery.
19.Refill gearbox using correct grade of oil.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids

44AUTOMATIC GEARBOX
10
REPAIR OIL SCREEN
Service repair no - 44.24.07
Renew
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Raise vehicle.
4.Drain oil and refit plug with new seal.
5.Detach heat shield at front exhaust pipe to
manifold.
6.Disconnect electrics from Lambda sensors.
7.Remove catalytic converter assembly.
8.Remove chassis cross-member from under
gearbox.
9.Disconnect dipstick tube at oil sump. Loosen
securing bolt at bell housing and move dipstick
aside.
10.Remove clamps securing oil sump. Note their
locations for refit and withdraw sump.
11.Remove gasket and clean gasket mating faces.
12.Remove securing screws and detach oil screen
and suction pipe, taking care to retain suction
pipe spacer, discard 'O' ring seal.13.Detach suction pipe from oil screen, discard 'O'
ring seal.
14.Clean oil screen and blow out with airline.
15.Clean suction pipe.
16.Fit new 'O' ring seals to oil screen using light
grease to aid assembly.
17.Fit oil screen and suction pipe with spacer and
secure with three bolts.
18.Refit oil sump using a new gasket.
19.Connect dipstick tube to oil sump and tighten
bolt at bell housing.
20.Refit chassis cross-member.
21.Refit catalytic converter assembly
22.Connect electrics to Lambda sensors.
23.Connect heat shield front pipe to manifold.
24.Connect battery.
25.Refill gearbox oil system using correct grade of
oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids

ZF
11
REPAIR CONTROL UNIT
Remove
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Raise vehicle.
4.Drain oil and refit plug with new seal.
5.Detach heat shield at front exhaust pipe to
manifold.
6.Disconnect electrics from Lambda sensors.
7.Remove catalytic converter assembly.
8.Remove chassis cross-member from under
gearbox.
9.Disconnect dipstick tube at oil sump. Loosen
securing bolt at bell housing and move dipstick
aside.
10.Remove clamps securing oil sump. Note their
locations for refit and withdraw sump.
11.Remove gasket and clean gasket mating faces.
12.Remove securing screws and detach oil screen
and suction pipe, taking care to retain suction
pipe spacer, discard 'O' ring seal.
13.Remove securing screws and detach control unit
from casing.

44AUTOMATIC GEARBOX
12
REPAIR Oil seal replacement
14.Remove circlips and springs from control unit.
Note locations of long and short springs.
15.Using seal replacer/remover LST113 remove
and discard seals.
16.Clean control unit, springs and circlips and check
that they are satisfactory for further use.
17.Fit new seals to control unit using LST113,
ensure seals are fully seated.
18.Fit springs to locations noted during removal and
secure with circlips.
Refit
19.Fit control unit to gearbox, locating throttle valve
behind cam and engaging selector quadrant with
manual valve.
20.Loosely fit securing screws.21.Manually open throttle linkage to full throttle
position.
22.Engage special tool LST 109 between control
unit and throttle valve pin.
23.Set correct distance between control unit and
cam.
24.Remove special tool and close throttle.
25.Fit new 'O' ring seals to oil screen using light
grease to aid assembly.
26.Fit oil screen and suction pipe with spacer and
secure with three bolts.
27.Refit oil pan using a new gasket.
28.Connect dipstick tube to oil sump and tighten
bolt at bell housing.
29.Refit chassis cross member.
30.Refit catalytic converter assembly
31.Connect electrics to Lambda sensors.
32.Connect heat shield front pipe to manifold.
33.Connect battery.
34.Refill gearbox oil system using correct grade of
oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids

ZF
13
REPAIR KICKDOWN CABLE
Service repair no - 44.15.01
Remove
1.Site vehicle on a four post ramp [hoist].
2.Select neutral 'N' gear lever.
3.Disconnect battery negative lead.
4.Disconnect kickdown cable at throttle linkage.
5.Release outer cable locknut.
6.Disconnect cable from mounting bracket.
7.Release cable from bracket attached to cylinder
head.
8.Feed cable through to underside of vehicle.
9.Raise vehicle on ramp [hoist].
10.Drain oil and refit plug with new seal.
11.Detach heat shield at front exhaust pipe to
manifold.
12.Disconnect electrics from Lambda sensors.
13.Remove catalytic converter assembly.
14.Remove chassis cross-member from under
gearbox.
15.Disconnect dipstick tube at oil sump. Loosen
securing bolt at bell housing and move dipstick
aside.
16.Remove clamps securing oil sump. Note their
locations for refit, and withdraw sump.
17.Pull kickdown inner cable to fully open valve
cam. Wedge cam in this position.
18.Release cable from cam by pushing inner cable
into outer casing and detaching cable nipple
from cam.
19.Using special tool LST112 compress cable tangs
and remove cable from gearbox.
20.If cable is to be refitted remove 'O' ring seal and
clean cable assembly.
Refit
21.Fit new 'O' ring seal to cable and lubricate seal.
22.Fit cable to gearbox casing ensuring it is
correctly seated.
23.Fit inner cable nipple to its location on cam.
NOTE: When a new cable is fitted, to help
locate nipple to cam, introduce a curve
into the cable. Do not bend or kink cable.24.Remove wedge from cam and ensure nipple
remains engaged.
25.Feed free end of cable assembly into engine
compartment.
26.Refit oil pan using a new gasket.
27.Connect dipstick tube to oil sump and tighten
bolt at bell housing.
28.Refit chassis cross-member
29.Refit catalytic converter assembly
30.Connect electrics to Lambda sensors.
31.Connect heat shield front pipe to manifold.
32.Lower vehicle on ramp [hoist].
33.Fit cable to bracket at cylinder head.
34.Locate cable in mounting bracket, do not tighten
locknut.
35.Fit cable to throttle linkage.
36.Ensure throttle linkage is fully closed.
37.Adjust outer cable to achieve a gap of 0,25 to
1,25mm (dimension 'A') between end of outer
cable and crimped collar on inner cable.
38.Tighten locknuts and recheck gap.
NOTE: If fitting a new cable, and collar on
inner cable is loose, measure distance 'B'
on old cable. Crimp collar on new cable to
this dimension.
39.Reconnect battery negative lead.
40.Refill gearbox oil using correct grade of oil.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids

57STEERING
4
REPAIR
Refit
15.Position steering box to chassis side member,
ensuring locating peg is engaged. Tighten bolts
to
81 Nm.
16.Fit pinch bolt and nut securing universal joint to
power steering box. Tighten to
25 Nm.
17.Position tie bar, tighten bolts and nut to81 Nm,
starting with tie bar to mounting nut, then
loosen nut and bolts by one complete turn.
18.Check steering box, adjust if necessary.See
Adjustment, Power Steering Box
19.Refit drag link to drop arm tighten nut to40 Nm.
20.Fit undertray.
21.Lower vehicle to ground.
22.Remove plugs and refit pipes to steering box.
Tighten 16mm thread to
20 Nm.
14mm thread to15 Nm.
23.Remove filler cap. Fill reservoir to oil level mark
on dipstick. Use recommended fluid.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids
and bleed power steering system.See
Power Steering System - Bleed
24.Recheck fluid level and replace cap.
25.With engine running, test steering system for
leaks by holding steering in both full lock
directions.
CAUTION: Do not maintain this pressure
for more than 30 seconds in any one
minute, to avoid oil overheating and
possible seal damage.
26.Test drive vehicle: using both full lock directions,
to settle steering components. If possible, drive
vehicle over speed bumps and include harsh
braking.
WARNING: Do not test drive vehicle on
public highway.
27.Drive vehicle in a straight line on level ground
and stop.
28.Tighten tie bar to mounting nut to
110 Nm.
29.Tighten bolts securing tie bar to81 Nm.
30.Ensure steering wheel is correctly aligned when
wheels are positioned straight ahead.
31.If necessary reposition steering wheel.
See
Steering Wheel
32.Road test vehicle.